Stabilizer coating for machine embroidering

ABSTRACT

Embodiments provide for an embroidery process where a stabilizer coating (rather than a paper or fabric backing) is used to provide support for an embroidery design. In one embodiment, when applying the stabilizer coating, its viscosity is changed in order to adhere the stabilizer coating to a garment and provide sufficient support for the embroidery design.

BACKGROUND

Embroidery is the craft of decorating fabric or other materials using a needle to apply thread or yarn. Embroidery may also incorporate other materials such as pearls, beads, quills, and sequins. In modern days, embroidery is usually seen on caps, hats, coats, blankets, dress shirts, denim, dresses, stockings, and golf shirts. Embroidery is available with a wide variety of thread or yarn color and can include 3D designs which have exaggerated thicknesses.

Embroidery often requires a stabilizer (also called a backing) to provide support for the thread so that the design does not pucker or bunch up. A stabilizer is often used when embroidery is performed on soft, pliable fabrics such as cotton, wool, lace, polyester, and the like. Typically, a sheet of stabilizer and the fabric are hooped together (e.g., using a hooping frame) while embroidery is performed to create a design (e.g., text, picture, logo, etc.) on the exterior surface of the garment. The portion of the stabilizer, which is disposed on an interior side of the garment and not directly behind the embroidery, can be cut off. The stabilizer or backing material is typically made of non-woven material of varying thickness or other type of non-woven fabric which provides structural support for fabric and the corresponding embroidered design based on the type and thickness of the fabric being embroidered, the embroidery design including the number of stitches per inch required to create the embroidery and the properties of stabilizer material. But since the stabilizer comes in direct contact with the skin of the person wearing the garment it can be an irritant. Moreover, the stabilizer itself is expensive and the excess portion must typically be removed by a human, further driving up costs of embroidery. Lastly, removing excess stabilizer backing must be performed manually by a labor intensive and therefore expensive process.

SUMMARY

One embodiment described herein is an article that includes fabric, a stabilizer coating disposed on the fabric, and an embroidery design disposed on the fabric and within an area defined by the stabilizer coating.

Another embodiment described herein is a method that includes providing an article, applying a stabilizer coating onto the article, tensioning the article, and performing embroidery on the tensioned article in an area of the stabilizer coating.

Another embodiment described herein is a method that includes applying a stabilizer coating onto an article by changing a viscosity of the stabilizer coating and performing embroidery on the article in an area of the stabilizer coating.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited aspects are attained and can be understood in detail, a more particular description of embodiments described herein, briefly summarized above, may be had by reference to the appended drawings.

It is to be noted, however, that the appended drawings illustrate typical embodiments and are therefore not to be considered limiting; other equally effective embodiments are contemplated.

FIG. 1 illustrates an embroidery process, according to one embodiment.

FIG. 2 illustrates a stabilizer coating used in an embroidery process, according to one embodiment.

FIG. 3 is a flowchart for an embroidery process, according to one embodiment.

FIG. 4 is a flowchart for applying a stabilizer coating for an embroidery process, according to one embodiment.

FIG. 5 is a flowchart for applying a stabilizer coating for an embroidery process, according to one embodiment.

FIG. 6 is a flowchart for a 3D embroidery process, according to one embodiment.

DETAILED DESCRIPTION

The embodiments herein describe using a stabilizer coating rather than a typical paper or fabric backing for an embroidery process. Advantageously, the stabilizer coating can be applied on either an exterior or interior side of the garment, unlike typical backing material that for aesthetic reasons is always disposed on an interior side of the garment. The stabilizer coating can be applied using a variety of different techniques such as being sprayed, rolled, printed, brushed, or melted onto the garment. The stabilizer coating is any coating that can provide sufficient structural backing for embroidery where a viscosity of the coating was changed during its application to the garment. For example, the stabilizer coating (e.g., a pre-polymer) may be applied in a liquid state to the garment but then polymerized and dried before the embroidery is performed. In another example, a thin film thermoplastic polymer material may be placed on the garment and then heated such that the polymer material melts, adheres to the garment, and then solidifies to form the stabilizer coating.

In one embodiment, the area or boundary of the stabilizer coating matches (or is slightly larger) than the area or boundary of the embroidery design. Although the coating may be clear, because the design covers the stabilizer coating, the coating can have a color and still be disposed on an exterior surface of the garment without being noticed (i.e., without having a negative impact on the aesthetics of the garment). Further, disposing the stabilizer coating on the exterior surface ensures the coating does not irritate the skin of the person wearing the garment due to jagged or rough edges. In addition, placing the coating on the same side of the garment as the embroidery can simplify the manufacturing process since backing does not need to be placed on a first side of the garment (e.g., the interior side) while the embroidery is formed on the second, opposite side of the garment (e.g., the exterior side).

While the discussion below describes providing a stabilizer coating on a garment (e.g., a piece of clothing), the embodiments herein can be performed using various “articles” which can include, but are not limited to, a piece of clothing (e.g. shirts, pants, socks, shoes, shorts, coats, jackets, skirts, dresses, underwear, hats, headbands, etc.), accessories (e.g. wallet, purse, etc.), and homewares (e.g. towels, pillow cases, blankets, mats, etc.).

FIG. 1 illustrates an embroidery process 100, according to one embodiment.

The embroidery process 100 includes an application stage 105, curing stage 110, and embroidery stage 115. The application stage 105 includes a stabilizer dispenser 120 that places the material of the stabilizer coating onto a designated area 130 of the garment 125. In one embodiment, although not shown in FIG. 1 , the stabilizer coating is applied while the garment 125 is under tension. However, in another embodiment the stabilizer coating is applied when the garment 125 is not tensioned. Once applied, the garment 125 can be tensioned before embroidery is performed. For example, an area 130 of the garment 125 on which the stabilizer component is to be applied may be stretched using a hoop (e.g., a hooping frame). In another embodiment, the garment 125 is placed on a platen. For example, the garment may be placed on, and stretched by, a surface of the platen, or the platen may be placed within the garment and then stretched.

The stabilizer dispenser 120 is not limited to any particular technique for applying the stabilizer coating to the garment 125. In one embodiment, the stabilizer coating is applied in a liquid state (with a relatively low viscosity). In that case, the stabilizer dispenser 120 can spray, roll, brush, or otherwise apply the material of the stabilizer coating onto the garment 125. For example, the stabilizer coating may be a pre-polymer such as silicone or elastomeric polyurethane, polyester, or polyethylene. In one embodiment, the stabilizer coating polymerizes into a silicone elastomer film with physical characteristics similar to that of, e.g., DOWSIL™ 734 self-leveling sealant. The stabilizer coating may also polymerize into a foam with the help of blowing agents such as expandable hollow spheres (e.g. Nouryon Expancel®) or isocyanate and water after being applied to the garment 125. In one embodiment, the stabilizer dispenser 120 may apply a hot melt polymer such as a molten fibrous material (e.g., polypropylene, polyester, or polyethylene) that is ejected at high speed onto the area 130 to form the stabilizer coating. In some embodiments, the stabilizer may be 3D printed, on demand, localized to the area and shape, over printed graphics to create varying thickness layers for a high-fidelity embroidery embellishment that is capable of creating very high quality artwork that cannot be recreated using existing technology.

In another embodiment, the stabilizer dispenser 120 applies the material of the stabilizer coating in a solid state. For example, for a large-scale embroidery process where the same design is applied to many garments (e.g., a large order of 100 or more of the same design), it may be more efficient to cutout portions of material from a large sheet of the material of the stabilizer coating that have the same dimensions of the area 130. The cutout portions can then be placed at the areas 130 of the garment. A heating process can then be used to melt the material (and reduce its viscosity) and form the stabilizer coating on the garment 125.

In some cases, the stabilizer coating is selected according to its elasticity. In one embodiment, the stabilizer coating has a Young's modulus between 0.5 to 2000 MPa to provide stability during embroidering and provide durability when the garment is worn and goes through wash cycles. In some embodiments, the stabilizer coating can be stretched or elongated by more than 200% before breaking or losing its structural integrity.

Further, the stabilizer coating may include an adhesive that helps the stabilizer stick or adhere to the garment when in a state with low viscosity. The stabilizer coating can then be dried or cured to adhere to the garment.

The material of the stabilizer coating may be selected based on the garment 125 on which it is to be applied. For example, one type of stabilizer coating may be used on organic fabrics (e.g., cotton) and a different type of stabilizer coating may be used on synthetic fabrics (e.g., polyester, nylon, spandex, etc.). For example, stabilizer coatings applied as a hot melt may lead to poor results when applied on organic fabrics while providing good results when applied on synthetic fabrics. Instead, materials that rely on reactive chemistry (e.g., polyurethane) to form the stabilizer coatings may be better for organic fabrics.

The curing stage 110 can be used to change the phase or the viscosity and elasticity of the stabilizer coating 140 so that it adheres to the garment 125. For example, if the stabilizer coating 140 is applied in a liquid state (or relatively high viscosity and low elasticity), a heater 135 can dry or cure the coating 140 into a solid state (or relatively low viscosity and high elasticity). In another embodiment, the heater 135 can be replaced by a fan or air circulation device for curing the stabilizer coating 140. In any case, this change in phase or viscosity can be a physical process or a chemical reaction. In some embodiments, radiation or light of a certain wavelength may be used to cure the stabilizer.

In another embodiment, the stabilizer is applied to the article and humidity cured at room temperature over a specific time. In another embodiment, the heater 135 may melt, rather than cure, the stabilizer coating 140 so its viscosity changes and adheres to the garment 125. In that case, the curing stage 110 can be used as a both a heating and drying stage to melt the stabilizer coating 140 before then drying the coating 140 so it adheres to the garment 125.

During the embroidery stage 115, an embroidery apparatus 145 uses a head 150 (e.g., a sewing head) to form an embroidery design 155 (e.g., text, logo, image, etc.) in the area 130 on which the stabilizer coating 140 was formed. The embroidery apparatus 145 can include any number of heads 150 and use any different colors of thread or yarn in order to generate the design 155.

In one embodiment, the garment 125 is held in a fixed position while the head 150 moves in X and Y directions to form the design 155. In another embodiment, the head 150 remains stationary while the garment 125 is moved in the X and Y directions. In yet another embodiment, both the head 150 and the garment moves. For example, the garment 125 may be moved in the X direction while the head 150 moves in the Y direction when performing the embroidery.

In one embodiment, the design 155 is a 3D embroidery where the stabilizer coating 140 provides a defined height or height profile across the design 155. For example, a 3D embroidery process may use a thicker stabilizer coating 140 to provide a desired height for the design 155 relative a 2D embroidery process where the thickness of the stabilizer coating 140 may have a de minimis effect on the thickness or height of the design 155. In another example, the stabilizer coating surface is non-flat and renders a 3D topology. The flexibility provided by the application of the types of stabilizer coatings described herein enables the creation of more complex and previously difficult to achieve 3D embroidery designs.

FIG. 2 is a stabilizer coating 210 used in an embroidery process, according to one embodiment. FIG. 2 illustrates a portion of a garment 200 that is stretched by a hoop 205 (e.g., a hooping frame) that tensions the garment 200 within the hoop 205. While a hoop 205 is used in FIG. 2 , in other embodiments the tension may be applied by a platen or some other tensioning apparatus.

Applying tension helps to ensure the stabilizer coating 210 and the design 215 are applied on a flat surface without any wrinkles or sagging. In this example, the coating 210 and the design 215 are applied on the same surface of the garment 200. This may help with manufacturing since the stabilizer dispenser 120 and the embroidery apparatus 145 in FIG. 1 can operate on the same side of the garment 200 which avoids having to flip over the garment during the embroidery process.

As shown, the stabilizer coating 210 has a boundary (shown by the dotted lines) that substantially matches a shape of the design 215. As such, the area occupied by the design 215 may substantially match the area occupied by the stabilizer coating 210 on the garment 200. As used herein, substantially match means the boundaries of the stabilizer coating and the design 215 may be less than a few (e.g., five) millimeters apart at corresponding locations. In one embodiment, it may be desired to ensure that the boundary or area of the stabilizer coating 210 is slightly expanded or larger (e.g., 1-7 millimeters) than the boundary or area of the design 215 which may provide extra support to the design 215. Although the stabilizer coating 210 may not be completely covered by the thread of the design 215, the coating 210 may still not be viewable (or easily viewable) on the surface of the garment 200. In one embodiment, the stabilizer coating 210 is selected to have the same color as the garment 200 so it is less visible. Alternatively, the stabilizer coating 210 is selected to have a different color from the garment 200 or the thread for contrast enhancement to the garment color or the embroidery threads for rich, artistic, embroidery artworks. However, in one embodiment, the stabilizer coating 210 may be disposed on the opposite side of the garment 200 than the design 215 so there are no restrictions on the area of the stabilizer coating 210. Doing so may make the manufacturing process slightly more complicated, but the stabilizer coating 210 can be made to size without affecting the person wearing the garment 200. The stabilizer coating 210 can also be applied with one or more holes (i.e., an absence of the stabilizer material) within the boundary of the coating 210 to match the design of the embroidered art (if it does not have thread at that area of the design). With a traditional stabilizer, it's impractical to trim or tear away stabilizer material behind unembroidered areas that are inside the perimeter of the embroidered art when there are holes in the art design.

FIG. 3 is a flowchart of a method 300 for an embroidery process, according to one embodiment. At block 305, a tensioning apparatus tensions the garment. In one embodiment, the tensioning apparatus can be a hoop, hooping frame, platen, or wire frame. Further, the tensioning apparatus can tension the entire garment, or just a portion of the garment on which the stabilizer coating and the embroidery design are to be applied.

At block 310, a stabilizer dispenser applies a stabilizer coating onto the garment. As mentioned above, there are various different techniques for applying the stabilizer coating. Different techniques are described in detail in the flowcharts in FIGS. 4-6 .

In one embodiment, applying the stabilizer coating includes changing the viscosity of the material of the stabilizer coating. For example, the stabilizer coating may be changed from having a low viscosity to a high viscosity, which can result in the stabilizer coating having a liquid (or molten) state to having a solid state. Changing the viscosity of the stabilizer coating can permit it to adhere or attach to the garment. That is, when changing from low to high viscosity, the stabilizer coating may adhere to the garment to form a solid film that provides the necessary support for performing the embroidery process. In some embodiments, the stabilizer may be aerosolized and may be applied in the form of a spray. In some embodiments, the stabilizer is applied on the front side garment in such conditions to allow the stabilizer material to flow, diffuse around the fibers to encapsulate the fibers, diffuse into the fabric layer, with controlled thickness, and once properly cured, structurally adheres to the fibers of the fabric(s) forming the garment without chemically bonding to the fibers.

In some embodiments, the stabilizer coating is applied to the garment before applying any tension to the garment. That is, the stabilizer coating is applied while the garment is not under tension. In one embodiment, the stabilizer coating is applied and cured before the garment is tensioned in preparation of the embroidery process. In another embodiment, the stabilizer coating is applied but then tensioned before being cured. However, in some embodiments such as method 300, the stabilizer coating is applied to the garment and is cured after placing the garment under some tension. In some embodiments, the amount of tension applied to the garment may be adjusted based on a variety of factors, including the fabric thickness or weight, the type of fabric, the embroidery design including the design requirements as to the number of stitches per inch, etc.

At block 315, an embroidery apparatus performs embroidery in the area of the stabilizer coating. In one embodiment, block 315 is performed after the stabilizer coating has been cured or dried such that it is in a solid state (e.g., a high viscosity). The embodiments herein are not limited to any particular type of embroidery apparatus or type of embroidery. That is, the stabilizer coating can be used in a variety of different embroidery processes and with a variety of different embroidery apparatuses.

The embroidery design can be 2D or 3D, where the stabilizer component can set the thickness, height, or height profile of the design. Further, the application of the stabilizer coating and the embroidery may be performed on the same side of the garment or on opposite sides. When performed on the same side, the shape and size of the stabilizer coating may be controlled to be substantially the same (or slightly larger) than the design so the coating (which may have a shiny appearance depending on the material chosen) is not readily visible. When performed on opposite sides of the garment, the area of the stabilizer coating may be less of a concern, but a non-irritant material may be selected to ensure the coating does not irritate the wearer's skin, which may not be a concern when the coating is applied on the exterior surface of the garment.

FIG. 4 is a flowchart of a method 400 for applying a stabilizer coating for an embroidery process, according to one embodiment. The method 400 is one example of applying a stabilizer coating onto a garment as described at block 310 of FIG. 3 . In some embodiments, the garment has already been tensioned, but this is not a requirement.

At block 405, the stabilizer dispenser applies the stabilizer coating onto the garment in a liquid state. The liquid state has a lower viscosity than a solid state obtained after the stabilizer coating has been dried or cured. The stabilizer coating can be applied by spraying, printing, brushing, or ejecting the coating material onto the garment. Further, the liquid may be applied as a foam or applied in a liquid and expands into a foam.

At block 410, the heater cures the stabilizer coating to convert it into a solid state. Further, curing the stabilizer can cause the material of the stabilizer coating to adhere to the garment to provide suitable support for the embroidery design. In one embodiment, curing the stabilizer changes the viscosity of the material so that the stabilizer coating is in a solid state.

The curing can be performed by applying heat, increased airflow, light (e.g., ultraviolet light), combining two reactive components of a reactive chemistry, and the like. That is, curing can be performed by any process that changes the stabilizer coating from a liquid to a solid state. Curing can be a chemical or a physical process.

Once cured (e.g., the stabilizer coating is changed to a solid state), the method 400 can proceed to block 315 where the embroidery design is applied in the same area of the stabilizer coating. However, in some embodiments, the stabilizer may need not be cured or may be partially cured before the embroidery operation is performed

FIG. 5 is a flowchart of a method 500 for applying a stabilizer coating for an embroidery process, according to one embodiment. The method 500 is another example of applying a stabilizer coating onto a garment as described at block 310 of FIG. 3 . In some embodiments, the garment has already been tensioned, but this is not a requirement

At block 505, a cutting apparatus provides a thin film having a shape of a desired embroidery design. In one embodiment, the thin film may be provided in a rolled up sheet of material for the stabilizer component. The sheet can be unrolled so that the cutting apparatus can cutout portions from the sheet that have shapes that substantially match (or are slightly larger) than the embroidery design. This may be especially useful in a high-volume embroidery process where the same embroidery design (e.g., the same text, logo, or image) is being formed on a large number of garments. In some embodiments, in high-volume embroidery operations, the stabilizer may be directly pre-applied and cured onto the garment to be embroidered to increase processing speed by pre-applying and pre-curing the stabilizer.

For example, if the design contains text, the cutouts can have substantially the same boundary and size as the boundary and size of the text as shown in FIG. 2 above. In this manner, a large sheet of stabilizer material can be cut up into smaller portions that substantially match the shape and size of the desired embroidery design.

At block 510, the stabilizer dispenser places the thin film (e.g., the cutout portions) on the garments. In one embodiment, the thin film may be held on the garments by gravity (e.g., simply placed on top of the garment where the embroidery is to take place), or the stabilizer dispenser may attach the thin film using a temporary attachment technique. For example, the thin film may have an adhesive on one side so that the film sticks to the garment. Or the stabilizer dispenser may use pins to hold the thin film in place on the garment. In this manner, unlike in method 400, the material of the stabilizer component is initially placed on the garment in a solid state, rather than a liquid state.

At block 515, the heater heats the thin film to form a stabilizer coating adhered to the garment. Stated differently, the heater lowers the viscosity of the thin film so it is permanently adhered to the garment. This can include changing the thin film from a solid state to a liquid or molten state. Further, the heating process can cause a physical change or a chemical reaction in the thin film.

At block 520, the stabilizer coating is cooled so the viscosity increases again. For example, the stabilizer coating may have a solid state once cooled. Now, rather than being temporally attached to the garment, the stabilizer coating is permanently adhered to the garment and forms a suitable substrate for forming the embroidery design on the garment.

Once cooled (e.g., the stabilizer coating is changed to a solid state), the method 500 can proceed to block 315 where the embroidery design is applied in the same area of the stabilizer coating.

FIG. 6 is a flowchart of a method 600 for a 3D embroidery process, according to one embodiment. Typically, a 3D embroidery process is performed by using a mold or substrate that is placed on the same surface on which the embroidery is performed. A backing material may still be placed on the opposite side of the surface to provide additional support. The embroidery design is then formed on the mold or substrate whose thickness gives the embroidery design its depth or height. However, in embodiments according to the present disclosure, instead of using a separate mold or substrate, in the method 600 the stabilizer coating can be used to perform both functions—i.e., to provide thickness so the design becomes 3D, as well as provide sufficient support for the design.

At block 605, a designer determines a desired height of the 3D embroidery design. That is, in addition to selecting the color of the thread, the size of the design, etc., the designer can also indicate the thickness or height of the design on the garment (e.g., how far the design sticks out from the exterior surface of the garment).

At block 610, the stabilizer dispenser determines the appropriate thickness of the stabilizer coating to achieve the desired height of the 3D design. That is, the stabilizer dispenser determines how thick the stabilizer coating should be in order to result in a 3D design with the desired height. In some embodiments, by closely adjusting the amount of stabilizer dispensed in any given location, thereby producing a 3D height profile as the foundation for the embroidered art, complex 3D designs may be formed that are not possible with traditional 3D methods.

At block 615, the stabilizer dispenser applies a stabilizer coating with the desired thickness at the location for the 3D design. In one embodiment, the stabilizer dispenser may perform multiple coats of the stabilizer coating (curing each coat) to build up a stabilizer coating with the desired thickness. In another embodiment, the stabilizer dispenser applies just one, thick coat of the stabilizer material (e.g., as a foam or gel) which has a sufficient thickness.

Once the extra thick stabilizer coating is solidified, the method 600 can proceed to block 315 where the embroidery design is applied in the same area of the stabilizer coating.

In the current disclosure, reference is made to various embodiments. However, it should be understood that the present disclosure is not limited to specific described embodiments. Instead, any combination of the following features and elements, whether related to different embodiments or not, is contemplated to implement and practice the teachings provided herein. Additionally, when elements of the embodiments are described in the form of “at least one of A and B,” it will be understood that embodiments including element A exclusively, including element B exclusively, and including element A and B are each contemplated. Furthermore, although some embodiments may achieve advantages over other possible solutions or over the prior art, whether or not a particular advantage is achieved by a given embodiment is not limiting of the present disclosure. Thus, the aspects, features, embodiments and advantages disclosed herein are merely illustrative and are not considered elements or limitations of the appended claims except where explicitly recited in a claim(s). Likewise, reference to “the invention” shall not be construed as a generalization of any inventive subject matter disclosed herein and shall not be considered to be an element or limitation of the appended claims except where explicitly recited in a claim(s).

As will be appreciated by one skilled in the art, embodiments described herein may be embodied as a system, method or computer program product. Accordingly, embodiments may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, embodiments described herein may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.

Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.

Computer program code for carrying out operations for embodiments of the present disclosure may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).

Aspects of the present disclosure are described herein with reference to flowchart illustrations or block diagrams of methods, apparatuses (systems), and computer program products according to embodiments of the present disclosure. It will be understood that each block of the flowchart illustrations or block diagrams, and combinations of blocks in the flowchart illustrations or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the block(s) of the flowchart illustrations or block diagrams.

These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other device to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the block(s) of the flowchart illustrations or block diagrams.

The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process such that the instructions which execute on the computer, other programmable data processing apparatus, or other device provide processes for implementing the functions/acts specified in the block(s) of the flowchart illustrations or block diagrams.

The flowchart illustrations and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart illustrations or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the Figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order or out of order, depending upon the functionality involved. It will also be noted that each block of the block diagrams or flowchart illustrations, and combinations of blocks in the block diagrams or flowchart illustrations, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.

While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. 

1-6. (canceled)
 7. A method comprising: providing an article; applying a stabilizer coating onto an area of the article corresponding to a size and shape of an embroidered pattern to be applied to the area, wherein the area of the article corresponding to the size and shape of the embroidered pattern is less than an entire area of the article; tensioning the article; and performing embroidery on the stabilizer coating of the tensioned article to create the embroidered pattern, wherein the stabilizer coating provides sufficient structural support to the area of the article corresponding to the size and shape of the embroidered pattern such that a backing material is not used during the embroidery.
 8. The method of claim 7, wherein applying the stabilizer coating onto the area of the article corresponding to the size and shape of the embroidered pattern to be applied to the area comprises: applying the stabilizer coating in a liquid state or as a foam, the method further comprising: curing the stabilizer coating to convert it into a solid state before performing the embroidery.
 9. The method of claim 8, wherein the stabilizer coating is a polymer applied in the liquid state to the article.
 10. The method of claim 9, wherein the stabilizer coating comprises at least one of polyurethane, polyester, or polyethylene.
 11. The method of claim 8, wherein the liquid state of the stabilizer coating is a hot melt of fibrous material.
 12. The method of claim 7, wherein applying the stabilizer coating onto the area of the article corresponding to the size and shape of the embroidered pattern to be applied to the area comprises: providing a thin film having a shape and a size that substantially matches a size and shape of the embroidered pattern, wherein the stabilizer coating comprises the thin film; placing the thin film on the article; and heating the thin film to melt and bond the thin film to the article, wherein the stabilizer coating comprises the bonded thin film.
 13. The method of claim 7, wherein applying the stabilizer coating onto the area of the article corresponding to the size and shape of the embroidered pattern to be applied to the area comprises: determining a desired height of a 3D design corresponding to the embroidered pattern; determining a thickness of the stabilizer coating to achieve the desired height; applying the stabilizer coating onto the area of the article at a first thickness; and applying the stabilizer coating with the determined thickness at a location of the 3D design, wherein the first thickness is less than the determined thickness.
 14. The method of claim 7, wherein the area of the article corresponding to the size and shape of the embroidered pattern is larger than an area occupied by the embroidered pattern.
 15. The method of claim 14, wherein a boundary of the area of the article corresponding to the size and shape of the embroidered pattern is less than 7 millimeters from a boundary of the area of the embroidered pattern.
 16. The method of claim 7, wherein the stabilizer coating is disposed on an exterior surface of the article.
 17. The method of claim 7, wherein the article is tensioned before the stabilizer coating is applied to the area of the article.
 18. The method of claim 7, wherein the article is tensioned after the stabilizer coating is applied to the area of the article.
 19. A method of providing an embroidered article, the method comprising: providing an article, the article comprising a substrate layer; applying a liquid polymer stabilizer coating onto an area of the substrate layer corresponding to a size and shape of an embroidered pattern to be applied to the area, wherein: the area of the substrate layer corresponding to the size and shape of the embroidered pattern is less than an entire area of the article; and a viscosity of the stabilizer coating increases after the stabilizer coating is applied; and performing embroidery on the stabilizer coating to produce the embroidered article, wherein the stabilizer coating provides sufficient structural support such that a backing material is not used during the embroidery.
 20. The method of claim 19, wherein applying the liquid polymer stabilizer coating comprises: applying the stabilizer coating in a liquid state with a first viscosity, the method further comprising: curing the stabilizer coating to increase the viscosity of the stabilizer coating to a second viscosity before performing the embroidery.
 21. The method of claim 19, wherein applying the liquid polymer stabilizer coating comprises: providing a thin film with a first viscosity and having a shape that substantially matches or is slightly larger than a size and shape of the embroidered pattern; placing the thin film on the substrate layer; and heating the thin film to lower its viscosity to a second viscosity to bond the thin film to the substrate layer, wherein the stabilizer coating comprises the thin film.
 22. The method of claim 21, further comprising curing the stabilizer coating to increase the viscosity of the stabilizer coating to a third viscosity before performing the embroidery.
 23. (canceled)
 24. The method of claim 13, wherein applying the stabilizer coating with the determined thickness at a location of the 3D design comprises: (a) applying a layer of the stabilizer coating; (b) curing the layer of the stabilizer coating; and (c) repeating (a) and (b) until the stabilizer coating is at the determined thickness.
 25. The method of claim 19, wherein the stabilizer coating remains a separate layer from the substrate layer after performing embroidery on the stabilizer coating. 